COOLING SYSTEM - automecanicoautomecanico.com/auto2043/neonbelt01.pdfThe radiator cooling fan is a...

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PL COOLING SYSTEM 7 - 1

COOLING SYSTEM

TABLE OF CONTENTS

page page

ESCRIPTION AND OPERATIONCOOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 1COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2COOLANT PERFORMANCE . . . . . . . . . . . . . . . . . . 2COOLANT RECOVERY SYSTEM . . . . . . . . . . . . . . 3ENGINE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . 3RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3RADIATOR COOLING FAN MODULE. . . . . . . . . . . 3COOLING SYSTEM PRESSURE CAP . . . . . . . . . . 4RADIATOR HOSES AND CLAMPS . . . . . . . . . . . . 5WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 5AUTOMATIC TRANSMISSION OIL COOLER. . . . . 6ACCESSORY DRIVE BELTS . . . . . . . . . . . . . . . . . 6ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . . 6IAGNOSIS AND TESTINGCOOLING SYSTEM DIAGNOSIS . . . . . . . . . . . . . . 7ENGINE THERMOSTAT TESTING . . . . . . . . . . . . 14ACCESSORY DRIVE BELT DIAGNOSIS. . . . . . . . 14WATER PUMP DIAGNOSIS . . . . . . . . . . . . . . . . 15COOLING SYSTEM FLOW CHECK . . . . . . . . . . . 15ELECTRIC FAN MOTOR TEST. . . . . . . . . . . . . . . 15COOLANT CONCENTRATION TESTING. . . . . . . . 15TESTING COOLING SYSTEM FOR LEAKS . . . . . 15PRESSURE CAP TO FILLER NECK SEAL

PRESSURE RELIEF CHECK . . . . . . . . . . . . . . . 16PRESSURE TESTING COOLING SYSTEM

PRESSURE CAP . . . . . . . . . . . . . . . . . . . . . . . 16LOW COOLANT LEVEL AERATION . . . . . . . . . . . 17DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17TEMPERATURE GAUGE INDICATION . . . . . . . . . 17ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . 17ERVICE PROCEDURESCOOLANT LEVEL CHECK—ROUTINE. . . . . . . . . 17

COOLANT—ADDING ADDITIONAL. . . . . . . . . . . 18COOLANT LEVEL—SERVICING . . . . . . . . . . . . . 18COOLING SYSTEM—DRAINING. . . . . . . . . . . . . 19COOLING SYSTEM—REFILLING . . . . . . . . . . . . 19

REMOVAL AND INSTALLATIONWATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 19WATER PUMP INLET TUBE . . . . . . . . . . . . . . . . 20ENGINE THERMOSTAT . . . . . . . . . . . . . . . . . . . . 20RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21RADIATOR DRAINCOCK . . . . . . . . . . . . . . . . . . . 22COOLING FAN MODULE . . . . . . . . . . . . . . . . . . . 22COOLANT RECOVERY CONTAINER . . . . . . . . . . 23ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . . 24ACCESSORY DRIVE BELTS . . . . . . . . . . . . . . . . 24AUTOMATIC BELT TENSIONER & PULLEY . . . . 26

DISASSEMBLY AND ASSEMBLYCOOLING FAN MODULE . . . . . . . . . . . . . . . . . . . 26

CLEANING AND INSPECTIONWATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 28ACCESSORY DRIVE BELT INSPECTION. . . . . . . 28COOLING SYSTEM CAP . . . . . . . . . . . . . . . . . . . 28COOLING SYSTEM CLEANING . . . . . . . . . . . . . . 28RADIATOR FLUSHING . . . . . . . . . . . . . . . . . . . . 28REVERSE FLUSHING . . . . . . . . . . . . . . . . . . . . . 29CHEMICAL CLEANING . . . . . . . . . . . . . . . . . . . . 29

ADJUSTMENTSBELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 29

SPECIFICATIONSCOOLING SYSTEM CAPACITY . . . . . . . . . . . . . . 30TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 30

SPECIAL TOOLSCOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

ESCRIPTION AND OPERATION

OOLING SYSTEMThe cooling system consists of an engine coolingodule, thermostat, coolant, and a water pump to

irculate the coolant. The engine cooling module mayonsist of a radiator, electric fan motor, fan, shroud,oolant reserve system, transmission oil cooler, hoses,

clamps, air conditioning condenser and transmissionoil lines.

• When the Engine is cold: The thermostat isclosed and the cooling system has no flow throughthe radiator. The coolant flows through the engine,heater system and bypass.

• When the Engine is warm: Thermostat is openand the cooling system has flow through the radiator,engine, heater system, and bypass.

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7 - 2 COOLING SYSTEM PL

DESCRIPTION AND OPERATION (Continued)

Coolant flow circuit for the 2.0L engine is shown inFig. 1).

During any reassembly procedures all pipe fittingsn water jacket, and water box require cleaning andpplication of thread sealant for entire length ofhreads.

OOLANTThe cooling system is designed around the coolant.

he coolant must accept heat from engine blocketal and in the cylinder head area near the exhaust

alves. Then coolant carries this heat to the radiatorhere the tube/fin assemblies can give off the heat to

he air.Mopart Antifreeze or the equivalent is recom-ended for optimum cooling performance and corro-

ion protection when mixed to a freeze point of -37° C-35° F).

OOLANT REPLACEMENTRefer to Group 0, Lubrication and Maintenance for

chedule.

OOLANT PERFORMANCEPerformance is measurable. For heat transfer pureater excels (Formula = 1 btu per minute for each

Fig. 1 Cooling S1 – HEATER2 – HEAT UP3 – COOL DOWN4 – PRESSURE CAP5 – THERMOSTAT HOUSING

degree of temperature rise for each pound of water).This formula is altered when necessary additives tocontrol boiling, freezing, and corrosion are added asfollows:

• Pure Water (1 btu) boils at 100°C (212°F) andfreezes at 0°C (32°F).

• 100 Percent Glycol (.7 btu) can cause a hotengine and detonation and will raise the freeze pointto 22°C (-8°F).

• 50/50 Glycol and Water (0.82 btu) is the recom-mended combination that provides a freeze point of-37°C (-35°F). The radiator, water pump, enginewater jacket, radiator pressure cap, thermostat, tem-perature gauge, sending unit and heater are alldesigned for 50/50 glycol.

Where required, a 56 percent glycol and 44 percentwater mixture will provide a freeze point of -59°C(-50°F).

CAUTION: Richer mixtures cannot be measuredwith field equipment which can lead to problemsassociated with 100 percent glycol.

SELECTION AND ADDITIVESThe use of aluminum cylinder heads, intake mani-

folds, and water pumps requires special corrosion

m Operation6 – WATER PUMP7 – ENGINE8 – COOLANT RECOVERY SYSTEM TANK9 – RADIATOR

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rotection. Mopart Antifreeze or the equivalent isecommended for best engine cooling without corro-ion. When mixed only to a freeze point of -37°C-35°F) to -59°C (-50°F). If it looses color or becomesontaminated, drain, flush, and replace with freshroperly mixed solution.

OOLANT RECOVERY SYSTEMThis system works in conjunction with the radiator

ressure cap to utilize thermal expansion and con-raction of the coolant to keep the coolant free ofrapped air. The system provides space for expansionnd contraction. Also, the system provides a conve-ient and safe method for checking and adjusting theoolant level at atmospheric pressure without remov-ng the pressure cap. It also provides some reserveoolant to compensate for minor leaks and evapora-ion or boiling losses. All vehicles are equipped withhis system (Fig. 2).

Refer to Coolant Level Check, Deaeration, andressure Cap sections for operation and service.

NGINE THERMOSTATThe engine thermostat is located on the front of

he engine (radiator side) in the thermostat housing/ngine outlet connector. The thermostat has an airleed (vent) located in the flange and a O-ring forealing incorporate on it. There is a relief in the ther-ostat housing/outlet connector for the O-ring.The engine thermostat is a wax pellet driven,

everse poppet choke type. It is designed to providehe fastest warm up possible by preventing leakagehrough it and to guarantee a minimum engine oper-ting temperature of 88 to 93°C (192 to 199°F). Also,he thermostat will automatically reach wide open, toccommodate unrestricted flow to the radiator as

Fig. 2 Coolant Recovery System1 – RECOVERY HOSE2 – ENGINE COOLANT RECOVERY CONTAINER3 – PRESSURE CAP

temperature of the coolant rises in hot weather toaround 104°C (220°F). Above this temperature thecoolant temperature is controlled by the radiator, fan,and ambient temperature—not the thermostat.

A thermostats primary purpose is to maintainengine temperature in a range that will provide sat-isfactory engine performance and emission levelsunder all expected driving conditions. It also provideshot water (coolant) for heater performance. It doesthis by transferring heat from engine metal andautomatic transmission oil cooler (if equipped) tocoolant, moving this heated coolant to the heater coreand radiator, and then transferring this heat to theambient air.

RADIATORThe radiator is a down-flow type (vertical tubes)

with design features that provide greater strength,as well as sufficient heat transfer capabilities to keepthe engine coolant within operating temperatures.

The radiator functions as a heat exchanger, usingair flow across the exterior of the radiator tubes. Thisheat is then transferred from the coolant and intothe passing air.

The radiator has an aluminum core with plastictanks. Although stronger than brass, plastic tanksare subject to damage by impact. Always handle radi-ator with care.

RADIATOR COOLING FAN MODULEThe radiator cooling fan is a single speed electric

motor driven fan. The fan module includes an electricmotor, fan blade, and a support shroud that isattached to the radiator (Fig. 3).

Fig. 3 Radiator Fan1 – SCREWS2 – LOWER MOUNTS3 – FAN MOTOR ELECTRICAL CONNECTOR

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Radiator cooling fan control operation is accomplishedwo ways. The fan always runs when the air condition-ng compressor clutch is engaged. In addition to thisontrol, the fan is turned on by the temperature of theoolant which is sensed by the coolant temperature sen-or which sends the message to the Powertrain Controlodule (PCM). The PCM turns on the fan through a

an relay by grounding the relay’s coil. The fan relay isocated in the Power Distribution Center (PDC) (Fig. 4).efer to the label beneath the PDC cover for location of

an relay.

The PCM will actuate the fan relay whenever the A/Clutch is engaged regardless of coolant temperature andehicle speed. If the A/C clutch is not engaged, the PCMill actuate the fan relay when the coolant temperature

eaches approximately (97° C) 207° F and turns off thean relay when the coolant temperature drops topproximately (94°C) 201° F. The fan relay is alsourned off when the vehicle speed is above approxi-ately 100 Km/h (62 MPH). Refer to Group 8W, Wiringiagrams for circuity provided.If the cooling fan is inoperative or a Diagnostic

rouble Code (DTC) related to fan control has beenet, refer to the appropriate Powertrain Diagnosticanual for complete diagnostic procedures.

OOLING SYSTEM PRESSURE CAPThe cooling system pressure cap is located on the cool-

nt outlet housing near the front of the cylinder head.The cooling system will operate at higher than atmo-

pheric pressure. The higher pressure raises the coolantoiling point, allowing increased radiator cooling capac-ty. The pressure cap will release cooling system pres-ure in a range of 97–124 kPa (14–18 psi).

Fig. 4 Power Distribution Center (PDC)

A vent valve located in the center of the cap allowsa small amount of coolant flow from the coolantreserve system (CRS) tank. This valve is springloaded in the closed position. However, it must befree to open during system cool-down. If the valve isstuck shut, the radiator hoses will collapse oncool-down. Clean the vent valve (Fig. 5) toensure proper sealing function.

There is a gasket in the cap that seals to the top ofthe filler neck so that vacuum is maintained to drawcoolant back into the system from the coolant reservesystem (CRS) tank.

RADIATOR COOLING FAN OPERATION CHART

Cooling Fan Control

A/C Off

Fan On: 97° C (207° F)

Fan Off: 94° C (201° F)Vehicle Speed >100 Km/h (62MPH)

A/C On

Fan On—regardless of coolant temperature or vehiclespeed.

Fig. 5 Cooling System Pressure Cap1 – PRESSURE RATING2 – FILLER NECK SEAL3 – PRESSURE VALVE
4 – VACUUM VENT VALVE (SHOWN IN SEALING POSITION)

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ADIATOR HOSES AND CLAMPS

ARNING: IF VEHICLE HAS BEEN RUN RECENTLY,AIT 15 MINUTES BEFORE WORKING ON VEHI-LE. RELIEVE PRESSURE BY PLACING A SHOPOWEL OVER THE CAP AND WITHOUT PUSHINGOWN ROTATE IT COUNTERCLOCKWISE TO THEIRST STOP. ALLOW FLUIDS TO ESCAPEHROUGH THE OVERFLOW TUBE AND WHEN THEYSTEM STOPS PUSHING OUT COOLANT ANDTEAM AND THE PRESSURE DROPS CONTINUEERVICE.

ARNING: CONSTANT TENSION HOSE CLAMPSRE USED ON MOST COOLING SYSTEM HOSES.HEN REMOVING OR INSTALLING, USE ONLY

OOLS DESIGNED FOR SERVICING THIS TYPE OFLAMP. ALWAYS WEAR SAFETY GLASSES WHENERVICING CONSTANT TENSION CLAMPS.

AUTION: A number or letter is stamped into theongue of constant tension clamps. If replacements necessary, use only a original equipment clampith matching number or letter (Fig. 6).

The hose clamps are removed by using Special Tool094 or equivalent constant tension clamp pliersFig. 7) to compress the hose clamp.

A hardened, cracked, swollen or restricted hosehould be replaced. Care should be taken not to dam-ge radiator inlet and outlet when removing hoses.Radiator hoses should be routed without any kinks

nd indexed as designed. The use of molded hoses isecommended.

Fig. 6 Spring Clamp Size Location1 – SPRING CLAMP SIZE LOCATION

Make sure hoses and connectors are clean and drybefore installation. Do not lubricate hoses wheninstalling.

Spring type hose clamps are used in all applica-tions. If replacement is necessary, replace with theoriginal Mopart equipment spring type clamp.

WATER PUMPThe water pump has a diecast aluminum body and

housing with a stamped steel impeller. The waterpump bolts directly to the cylinder block and isdriven by the timing belt (Fig. 8). Cylinder block towater pump sealing is provided by a rubber O-ring.

The water pump is the “heart” of the cooling sys-tem. It pumps the coolant through the engine block,cylinder head, heater core, and radiator.

NOTE: The water pump on all models can bereplaced without discharging the air conditioningsystem.

Fig. 7 Hose Clamp Tool1 – HOSE CLAMP TOOL 60942 – HOSE CLAMP

Fig. 8 Water Pump1 – CYLINDER BLOCK2 – PUMP BODY

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UTOMATIC TRANSMISSION OIL COOLEROil coolers are internal oil to coolant type, mounted

n the radiator lower tank (Fig. 9). Rubber oil lineseed the oil cooler and the automatic transmission.se only approved transmission oil cooler hose. Since

hese are molded to fit space available, molded hosesre recommended. Tighten Oil Cooler Hose Clampso 2 N·m (18 in. lbs.).

CCESSORY DRIVE BELTSThe accessory drive consist of two Poly-V type

rive belts (Fig. 10). One belt drives the generator,he other drives the power steering pump and aironditioning compressor (if equipped). The powerteering/air conditioning belt is tensioned by an auto-atically controlled belt tensioner. The generator

elt is manually tensioned using an adjusting boltnd a locking nut.

NGINE BLOCK HEATERThe heater is mounted in a core hole (in place of a

ore hole plug) in the engine block, with the heatinglement immersed in coolant (Fig. 11). The enginelock heater is available as an optional accessory.he heater is operated by ordinary house current

110 Volt A. C.) through a power cord and connectorehind the radiator grille.When in operation, the engine block heater can

rovide easier engine starting and faster warm-up,hen vehicle is operated in areas having extremely

ow temperatures.

Fig. 9 Automatic Transmission Oil Cooler1 – CLAMPS2 – HOSES

CAUTION: The power cord must be secured in itsretainer clips, and not positioned so it could con-tact linkages or exhaust manifolds and becomedamaged.

Fig. 10 Accessory Drive Belts1 – GENERATOR BELT2 – AUTOMATIC BELT TENSIONER3 – POWER STEERING PUMP/A/C COMPRESSOR BELT

Fig. 11 Engine Block Heater1 – CORE PLUG2 – BLOCK HEATER3 – POWER CORD

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IAGNOSIS AND TESTING

OOLING SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSE CORRECTION

TEMPERATURE GAUGE READSLOW

1. Has a Diagnostic Trouble Code(DTC) been set indicating a stuckopen engine thermostat?

1. Refer to On Board Diagnostic inGroup 25. Replace thermostat, ifnecessary. If a (DTC) has not beenset, the problem may be with thetemperature gauge.

2. Is the temperature gauge (ifequipped) connected to thetemperature gauge coolant sensoron the engine?

2. Check the connector at theengine coolant sensor. Refer toGroup 8E. Repair as necessary.

3. Is the temperature gauge (ifequipped) operating OK?

3. Check Gauge operation. Refer toGroup 8E. Repair as necessary.

4. Coolant level low during coldambient temperature, accompaniedby poor heater performance.

4. Check coolant level in the coolantrecovery/reserve container and theradiator. Inspect the system forleaks. Repair as necessary. Refer toWARNINGS in this section beforeremoving pressure cap.

TEMPERATURE GAUGE READSHIGH OR ENGINE COOLANTWARNING LAMP ILLUMINATES.COOLANT MAY OR MAY NOT BELOST FROM SYSTEM.

1. Trailer being towed, a steep hillbeing climbed, vehicle beingoperated in slow moving traffic, orengine idling during high ambient(outside) temperatures with airconditioning on. High altitudesCould aggravate these conditions.

1. This may be a temporarycondition and repair is notnecessary. Turn off the airconditioning and drive the vehiclewithout any of the previousconditions. Observe the temperaturegauge the gauge should return tothe normal range. If the gauge doesnot return to the normal range,determine the cause of theoverheating and repair. Refer toPOSSIBLE CAUSES in this section.

2. Is temperature gauge (ifequipped) reading correctly?

2. Check gauge. Refer to Group 8E.Repair as necessary.

3. Is temperature warning lamp (ifequipped) illuminatingunnecessarily?

3. Check warning lamp operation.Refer to Group 8E. Repair asnecessary.

4. Coolant low in recovery/reservecontainer and radiator?

4. Check for coolant leaks andrepair as necessary. Refer toChecking Cooling System for Leaksin this section.

5. Pressure cap not installed tightly.If cap is loose, boiling point ofcoolant will be lowered. Also referto the following step 6.

5. Tighten cap.


DIAGNOSIS AND TESTING (Continued)


TEMPERATURE GAUGE READSHIGH OR ENGINE COOLANTWARNING LAMP ILLUMINATES.COOLANT MAY OR MAY NOT BELOST FROM SYSTEM. (CONT.)

6. Poor seals at radiator cap. 6. (a) Check condition of cap andcap seals. Refer to Radiator capInspection. Replace cap ifnecessary.

(b) Check condition of filler neck. Ifneck is bent or damaged, replaceneck.

7. Coolant level low in radiator, butnot in coolant recovery/reservecontainer. This indicates theradiator is not drawing coolant fromthe coolant recovery/reservecontainer as the engine cools. Asthe engine cools, a vacuum isformed inside the cooling system. Ifthe radiator cap seals are defective,or the cooling system has a leak, avacuum cannot be formed.

7. (a) Check condition of radiatorcap and cap seals. Replace cap ifnecessary.

(b) Check condition of filler neck.Replace if damaged.

(c) Check condition of hose fromfiller neck to coolant container. Itshould be tight at both ends withoutany kinks or tears. Replace hose asnecessary.

(d) Check coolant recovery/reservecontainer and hose for blockage.Repair as necessary.

8. Freeze point of coolant notcorrect. Mixture ratio may be toorich.

8. Check coolant concentration.Refer to Coolant ConcentrationTesting in this section. Adjustglycol-to-water ration as required.

9. Coolant not flowing throughsystem.

9. Check for coolant flow at fillerneck with some coolant removed,engine warm, and thermostat open.Coolant should be observed flowingthrough filler neck. If flow is notobserved, determine reason for lackof flow and repair as necessary.

10. Radiator or A/C condenser finsare dirty or clogged.

10. Clean obstruction from fins.

11. Radiator core is plugged orcorroded.

11. Replace or re-core radiator.

12. Fuel or ignition systemproblems.

12. Refer to Fuel and IgnitionSystem groups for diagnosis. Alsorefer to the appropriate PowertrainDiagnostic Procedure manual.

13. Dragging Brakes. 13. Inspect brake system and repairas necessary. Refer to Group 5,Brakes for diagnosis.

14 Bug screen or other aftermarketaccessory is being used causingreduced air flow.

14. Remove bug screen oraccessory.

15. Thermostat partially orcompletely closed. This is moreprevalent on high mileage vehicles.

15. Check thermostat operation andreplace as necessary. Refer tothermostat in this section forprocedure.




16. Electric cooling fan notoperating properly.

16. Check electric fan operation andrepair as necessary.

17. Cylinder head gasket leaking. 17. Check cylinder head gasket forleaks. Refer to testing coolingsystem for leaks. For repairs, referto Group 9, Engine.

18. Heater core leaking. 18. Check heater core for leaks.Refer to Group 24, Heating and AirConditioning and repair asnecessary.

TEMPERATURE GAUGE READINGIS INCONSISTENT (FLUCTUATES,CYCLES OR IS ERRATIC)

1. The gauge may cycle up anddown. This is due to the cycling ofthe electric radiator fan.

1. A normal condition. No correctionis necessary. If gauge cycling isgoing into the hot zone, checkelectric fan operation and repair asnecessary. Refer to procedure inthis section.

2. During cold weather operationwith the heater blower in the highposition, the gauge reading maydrop slightly.

2. A normal condition. No correctionis necessary.

3, Temperature gauge or enginemounted gauge sensor is defectiveor shorted.

3. Check operation of gauge andrepair as necessary. Refer to Group8E, Instrument Panel and Gauges.

4. Gauge reading rises whenvehicle is brought to a stop afterheavy use (engine still running).

4. A normal condition. No correctionis necessary. The gauge shouldreturn to normal range after vehicleis driven.

5. Gauge reading high afterrestarting a warmed-up (hot)engine.

5. A normal condition. No correctionis necessary. The gauge shouldreturn to normal range after a fewminutes of engine operation.

6. Coolant level low in radiator (airwill build up in the cooling systemcausing the thermostat to openlate).

6. Check and correct coolant leaks.Refer to Testing Cooling System ForLeaks in the section.

7. Cylinder head gasket leakingallowing exhaust gas to entercooling system. This will causethermostat to open late.

7. (a) Check for cylinder headgasket leaks with a commerciallyavailable Block Leak Tester. Repairas necessary.

(b) Check for coolant in the engineoil. Inspect for white steam emittingfrom exhaust system. Repair asnecessary.

8. Water pump impeller loose onshaft.

8. Check water pump and replaceas necessary. Refer to Water Pumpin this section.

9. Loose drive belt (water pumpslipping).

9. Check drive belt and correct asnecessary.




10. Air leak on the suction side ofwater pump allows air to build up incooling system. This will cause thethermostat to open late.

10. Locate leak and repair asnecessary.

PRESSURE CAP IS BLOWINGOFF STEAM AND/OR COOLANTFLOWING INTO RECOVERYCONTAINER. TEMPERATUREGAUGE READING MAY BE ABOVENORMAL, BUT NOT HIGH.COOLANT LEVEL MAY BE HIGHIN RECOVERY CONTAINER.

1. Pressure relief valve in radiatorcap is defective.

1. Check condition of radiator capand seals. Refer to Radiator Cap inthis section. Replace as necessary.

COOLANT LOSS TO THEGROUND WITHOUT PRESSURECAP BLOWOFF. GAUGE ISREADING HIGH OR HOT.

1. Coolant leaks in radiator, coolingsystem hoses, water pump orengine.

1. Pressure test and repair asnecessary. Refer to Testing CoolingSystem For Leaks in this section.

DETONATION OR PRE-IGNITION(NOT CAUSED BY IGNITIONSYSTEM). GAUGE MAY OR MAYNOT BE READING HIGH.

1. Engine overheating. 1. Check reason for overheatingand repair as necessary.

2. Freeze point of coolant notcorrect.

2. Check the freeze point of thecoolant. Refer to CoolantConcentration Testing in thissection. Adjust glycol-to-water ratioas required.

HOSE OR HOSES COLLAPSEWHEN ENGINE IS COOLING

1. Vacuum created in coolingsystem on engine cool-down is notbeing relieved through coolantrecovery/reserve container system.

1. (a) Radiator cap relief valvestuck. Refer to Radiator Cap in thissection. Replace as necessary.

(b) Hose between coolantrecovery/reserve container andradiator is kinked. Repair asnecessary.

(c) Vent at coolant recovery/reservecontainer is plugged. Clean ventand repair as necessary.

(d) Recovery/reserve container isinternally blocked or plugged. Checkfor blockage and repair asnecessary.

ELECTRIC RADIATOR FANOPERATES ALL THE TIME.

1. Fan relay, powertrain controlmodule (PCM) or engine coolanttemperature sensor defective.

1. Refer to appropriate PowertrainDiagnostic Procedures manual foroperation of the DRB scan tool.Repair as necessary.

2. Check for low coolant level. 2. Repair as necessary.




ELECTRIC RADIATOR FAN WILLNOT OPERATE. GAUGE READINGHIGH OR HOT

1. Fan motor defective. 1. Refer to appropriate PowertrainDiagnostic Procedures manual foroperation of the DRB scan tool.Repair as necessary.

2. Fan relay, powertrain controlmodule (PCM) or engine coolanttemperature sensor defective.


3. Blown fuse in power distributioncenter (PDC).

3. Determine reason for blown fuseand repair as necessary.

NOISY FAN 1. Fan blade loose. 1. Replace fan blade assembly.Refer to Cooling System Fan in thissection.

2. Fan blade striking a surroundingobject.

2. Locate point of fan blade contactand repair as necessary.

3. Air obstructions at radiator or A/Ccondenser.

3. Remove obstructions and/orclean debris from radiator and/orA/C condenser.

4. Electric fan motor defective. 4. Refer to procedure in this section.

INADEQUATE AIR CONDITIONERPERFORMANCE (COOLINGSYSTEM SUSPECTED)

1. Radiator and/or air conditioningcondenser is restricted, obstructedor dirty.

1. Remove restriction and/or cleanas necessary.

2. Electric radiator fan not operatingwhen A/C is on.


3. Engine is overheating (heat maybe transferred from radiator to A/Ccondenser). High underhoodtemperature due to engineoverheating may also transfer heatto A/C components.

3. Correct overheating condition.Refer to this section.




INADEQUATE HEATERPERFORMANCE.

1. Has a diagnostic trouble code(DTC) been set?

1. Refer to On-Board Diagnostic inGroup 25, Emission ControlSystems.

2. Coolant level low. 2. Refer to testing cooling systemfor leaks in this section. Repair asnecessary.

3. Obstructions in heater hosefittings at engine.

3. Remove heater hoses at bothends and check for obstructions.Repair as necessary.

4. Heater hose kinked. 4. Locate kinked area and repair asnecessary.

5. Water pump is not pumpingcoolant to heater core. When theengine is fully warmed up, bothheater hoses should be hot to thetouch. The water pump drive beltmay be slipping causing poor waterpump operation.

5. Refer to water pump in thissection. Repair as necessary.

HEAT ODOR 1. Various heat shields are used atcertain driveline components. Oneor more of these shields may bemissing.

1. Locate missing shields andreplace or repair as necessary.

2. Is temperature gauge readingabove the normal range?

2. Refer to the previousTemperature Gauge Reads High inthese Diagnostic Charts. Repair asnecessary.

3. Is cooling fan operatingcorrectly?

3. Refer to Cooling System Fan inthis section for diagnosis. Repair asnecessary.

4. Has undercoating been appliedto any unnecessary component.

4. Clean undercoating as necessary.

5. Engine may be running richcausing the catalytic converter tooverheat.


POOR DRIVEABILITY(THERMOSTAT POSSIBLY STUCKOPEN). GAUGE MAY BE READINGLOW

1. For proper driveability, goodvehicle emissions and forpreventing build-up of engine oilsludge, the thermostat must beoperating properly. Has a diagnostictrouble code (DTC ) been set?

1. Refer to On-Board Diagnostics inGroup 25, Emission ControlSystems. DTC’s may also be checkusing the DRB scan tool. Refer tothe proper Powertrain DiagnosticProcedure manual for checking thethermostat if necessary.




STEAM IS COMING FROM FRONTOF VEHICLE NEAR GRILL AREAWHEN WEATHER IS WET,ENGINE IS WARMED UP,RUNNING, AND VEHICLE ISSTATIONARY. TEMPERATUREGAUGE IS IN NORMAL RANGE.

1. During wet weather, moisture(snow, ice or rain condensation) onthe radiator will evaporate when thethermostat opens. This openingallows heated water into theradiator. When the moisture contactthe hot radiator, steam may beemitted. This usually occurs in coldweather with no fan or airflow toblow it away.

1. Occasional steam emitting fromthis area is normal. No repair isnecessary.

COOLANT COLOR 1. Coolant color is not necessarilyan indication of adequate corrosionor temperature protection. Do notrely on coolant color for determiningcondition of coolant.

1. Check the freeze point of thecoolant. Refer to CoolantConcentration Testing in this sectionfor procedure. Adjust the glycol-to-water ratio as required.

COOLANT LEVEL CHANGES INCOOLANT RECOVERY/RESERVECONTAINER

1. Level changes are to beexpected as coolant volumefluctuates with engine temperature.If the level in the container wasbetween the FULL and ADD marksat normal engine operatingtemperature, the level should returnto within that range after operationat elevated temperatures.

1. A normal condition. No repair isnecessary.

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NGINE THERMOSTAT TESTINGThe thermostat is operated by a wax filled con-

ainer (pellet) which is sealed. When heated coolanteaches a predetermined temperature the wax pelletxpands enough to overcome the closing spring andater pump pressure, which forces the valve to open.oolant leakage into the pellet will cause a thermo-tat to fail open. Do not attempt to free up a thermo-tat with a screwdriver.The thermostat that opens too soon type failureode is included in the on-board diagnosis. The

check engine light will not be lit by an open too sooncondition. If it has failed open, a diagnostic troublecode (DTC) will be set. Do not change a thermostatfor lack of heater performance or temperature gaugeposition, unless a DTC is present. See Diagnosis forother probable causes. Thermostat failing shut is thenormal long term mode of failure, and normally, onlyon high mileage vehicles. The temperature gauge willindicate this. Refer to Diagnosis in this section.

CCESSORY DRIVE BELT DIAGNOSIS


BELT SLIPPAGE 1. Belt slipping because ofinsufficient tension.

1. Retension generator belt.Replace the power steering belt’sautomatic belt tensioner.

2. Belt excessively glazed orhardened from heat and excessiveslippage.

2. Replace belt.

3. Incorrect belt. 3. Replace belt.

4. Driven component bearingfailure.

4. Replace faulty component.

5. Belt or pulley subjected tosubstance (belt dressing, oil,ethylene glycol) that has reducedfriction.

5. Replace belt and clean pulleys.

BELT NOISE (OBJECTIONABLESQUEAL, SQUEAK, OR RUMBLE)

1. Belt slippage. 1. Retension generator belt, replacebelt, or automatic belt tensioner.

2. Foreign material imbedded inbelt.

2. Replace belt.

3. Non-uniform belt. 3. Replace belt.

4. Misaligned pulley(s). 4. Align accessories.

5. Non-uniform groove or eccentricpulley.

5. Replace pulley(s).

6. Bearing noise. 6. Locate and repair.

BELT ROLLED OVER IN GROOVEOR BELT JUMPS OFF

1. Broken cord in belt. 1. Replace belt.

2. Belt tension too loose, or tootight.

2. Retension generator belt.Replace the power steering belt’sautomatic belt tensioner.

3. Misaligned pulleys. 3. Align accessories.

4. Non-uniform grooves or eccentricpulley.

4. Replace pulley(s).

5. Foreign object(s) in grooves. 5. Remove foreign objects ingroove.

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ATER PUMP DIAGNOSISA quick flow test to tell whether or not the pump isorking is to see if the heater warms properly. Aefective pump will not be able to circulate heatedoolant through the long heater hose.Another flow test to help determine pump opera-

ion:

ARNING: DO NOT remove radiator cap if the cool-ng system is hot or under pressure.

(1) Remove cooling system pressure cap.(2) Remove a small amount of coolant from the

ystem.(3) Start the engine and warm up until thermostat

pens.(4) With the thermostat open and coolant level low,

isually inspect for coolant flow. If flow is present,he water pump is pumping coolant through the sys-em.

OOLING SYSTEM FLOW CHECKTo determine whether coolant is flowing through

he cooling system, use the following procedures:(1) If engine is cold, idle engine until normal oper-

ting temperature is reached. Then feel the upperadiator hose. If it is hot, coolant is circulating.

ARNING: DO NOT REMOVE THE COOLING SYS-EM PRESSURE CAP WITH THE SYSTEM HOT ANDNDER PRESSURE BECAUSE SERIOUS BURNSROM COOLANT CAN OCCUR.

(2) Remove pressure cap when engine is cold,emove small amount of coolant Idle engine untilhermostat opens, you should observe coolant flowhile looking down the filler neck. Once flow isetected install the pressure cap.

LECTRIC FAN MOTOR TESTRefer to Powertrain Diagnostic Manual for proce-

ure.

OOLANT CONCENTRATION TESTINGCoolant concentration should be checked when any

dditional coolant was added to system or after aoolant drain, flush and refill. The coolant mixtureffers optimum engine cooling and protection againstorrosion when mixed to a freeze point of -37°C-34°F) to -59°C (-50°F). The use of a hydrometer or aefractometer can be used to test coolant concentra-ion.

A hydrometer will test the amount of glycol in aixture by measuring the specific gravity of the mix-

ure. The higher the concentration of ethylene glycol,he larger the number of balls that will float, and

higher the freeze protection (up to a maximum of70% by volume glycol).

A refractometer will test the amount of glycol in acoolant mixture by measuring the amount a beam oflight bends as it passes through the fluid.

Some coolant manufactures use other types of gly-cols into their coolant formulations. Propylene glycolis the most common new coolant. However, propyleneglycol based coolants do not provide the same freez-ing protection and corrosion protection and is onlyrecommended for limited usage. Refer to appropriateTechnical Service Bulletin(s) regarding use of propy-lene glycol based coolants.

CAUTION: Do not mix types of coolant—corrosionprotection will be severely reduced.

Because ethylene glycol and propylene glycol donot have the same specific gravities, the use of ahydrometer will be inaccurate. Therefore, SpecialTool 8286 refractometer, is recommended when test-ing either ethylene or propylene glycol coolants.

TESTING COOLING SYSTEM FOR LEAKSThe system should be full. With the engine not

running, wipe the filler neck sealing seat clean.Attach a radiator pressure tester to the filler neck,

as shown in (Fig. 12) and apply 104 kPa (15 psi)pressure. If the pressure drops more than 2 psi in 2minutes, inspect the system for external leaks.

Move all hoses at the radiator and heater whilesystem is pressurize at 15 psi, since some leaks occurdue to engine rock while driving.

If there are no external leaks after the gauge dialshows a drop in pressure, detach the tester. Start theengine, and run the engine to normal operating tem-perature in order to open the thermostat and allow

Fig. 12 Pressure Testing Cooling System—Typical1 – PRESSURE TESTER

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he coolant to expand. Reattach the tester. If the nee-le on the dial fluctuates it indicates a combustioneak, usually a head gasket leak.

ARNING: WITH THE PRESSURE TESTER INLACE PRESSURE BUILDS UP QUICKLY. ANYXCESSIVE PRESSURE BUILD-UP DUE TO CON-INUOUS ENGINE OPERATION MUST BEELEASED TO A SAFE PRESSURE POINT. NEVERERMIT PRESSURE TO EXCEED 138 kPa (20 psi).

If the needle on the dial does not fluctuate, racehe engine a few times. If an abnormal amount ofoolant or steam is emitted from the tail pipe, it mayndicate a faulty head gasket, cracked engine block,r cracked cylinder head.There may be internal leaks, which can be deter-ined by removing the oil dipstick. If water globules

ppear intermixed with the oil, it indicates an inter-al leak in the engine. If there is an internal leak,he engine must be disassembled for repair.

RESSURE CAP TO FILLER NECK SEALRESSURE RELIEF CHECKThe pressure cap upper gasket (seal) pressure

elief can be checked by removing the overflow hoset the radiator filler neck nipple (Fig. 13). Attach theadiator pressure tester to the filler neck nipple,nd pump air into the system. The pressure cappper gasket should relieve pressure at 69-124 kPa10-18 psi), and hold pressure at 55 kPa (8 psi) min-mum.

ARNING: THE WARNING WORDS DO NOT OPENOT ON THE PRESSURE CAP IS A SAFETY PRE-AUTION. WHEN HOT, THE COOLING SYSTEMUILDS UP PRESSURE. TO PREVENT SCALDINGR OTHER INJURY, THE PRESSURE CAP SHOULDOT BE REMOVED WHILE THE SYSTEM IS HOTND/OR UNDER PRESSURE.

There is no need to remove the pressure cap at anyime except for the following purposes:

• Check and adjust coolant freeze point• Refill system with new coolant• Conducting service procedures• Checking for leaks

ARNING: IF VEHICLE HAS BEEN RUN RECENTLY,AIT 15 MINUTES BEFORE REMOVING CAP.LACE A SHOP TOWEL OVER THE CAP, AND WITH-UT PUSHING DOWN, ROTATE IT COUNTER-LOCKWISE TO THE FIRST STOP. ALLOW FLUIDS

TO ESCAPE THROUGH THE OVERFLOW TUBE.WHEN THE SYSTEM STOPS PUSHING COOLANTAND STEAM INTO THE CRS TANK AND PRESSUREDROPS, PUSH DOWN ON THE CAP AND REMOVEIT COMPLETELY. SQUEEZING THE RADIATORINLET HOSE WITH A SHOP TOWEL (TO CHECKPRESSURE) BEFORE AND AFTER TURNING TOTHE FIRST STOP IS RECOMMENDED.

PRESSURE TESTING COOLING SYSTEMPRESSURE CAP

Dip the pressure cap in water; clean off any depos-its on the vent valve or its seat, and apply the cap toend of radiator pressure tester (Fig. 14). Working theplunger, increase the pressure to 104 kPa (15 psi) onthe gauge. If the pressure cap fails to hold pressureof at least 97 kPa (14 psi), replace the cap.

Fig. 13 Cooling System Pressure Cap1 – PRESSURE RATING2 – FILLER NECK SEAL3 – PRESSURE VALVE4 – VACUUM VENT VALVE (SHOWN IN SEALING POSITION)

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AUTION: The radiator pressure tester is very sen-itive to small air leaks that will not cause coolingystem problems. A pressure cap that does notave a history of coolant loss should not beeplaced just because it leaks slowly when testedith this tool. Add water to the tool. Turn the toolpside down, and recheck the pressure cap to con-

irm that the cap is faulty.If the pressure cap tests properly while posi-

ioned the on radiator pressure tester, but will notold pressure or vacuum when positioned on the

iller neck, inspect the filler neck and cap top gas-et for irregularities that may prevent the cap fromealing properly.

OW COOLANT LEVEL AERATION• Will cause corrosion in the system.• High reading shown on the temperature gauge.• Air in the coolant will also cause loss of flow

hrough the heater.• Exhaust gas leaks into the coolant can also

ause the above problems.

EAERATIONAir can only be removed from the system by gath-

ring under the pressure cap. On the next heat up itill be pushed past the pressure cap into the coolant

ecovery container by thermal expansion of the cool-nt. It then escapes to the atmosphere in the coolantecovery container and is replaced with coolant onool down.

EMPERATURE GAUGE INDICATIONAt idle the temperature gauge could rise slowly to

bout 1/2 gauge travel. The fan will come on and theauge could drop to about 1/3 gauge travel, this isormal.

Fig. 14 Pressure Testing Radiator Cap1 – PRESSURE CAP2 – PRESSURE TESTER

ENGINE BLOCK HEATERIf heater unit does not operate (Fig. 15), possible

causes can be either the power cord or the heater ele-ment. Test the power cord for continuity with a 110-volt voltmeter or 110-volt test light. Test heaterelement continuity with an ohmmeter or a 12-volttest light.

CAUTION: To prevent damage, the power cordmust be secured in its retainer clips and away fromany components that may cause abrasion or dam-age, such as linkages, exhaust components, etc.

SERVICE PROCEDURES

COOLANT LEVEL CHECK—ROUTINE

NOTE: Do not remove radiator cap for routine cool-ant level inspections.

The coolant recovery/reserve system provides aquick visual method for determining the coolant levelwithout removing the radiator cap. Simply observe,with the engine idling and warmed up to normaloperating temperature, that the level of the coolantin the recovery/reserve container (Fig. 16) is betweenthe FULL HOT and ADD marks.


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SERVICE PROCEDURES (Continued)

OOLANT—ADDING ADDITIONAL

OTE: The radiator cap should not be removed.

When additional coolant is needed, it should bedded to the coolant recovery/reserve container (Fig.

Fig. 17 Coolant Recovery Contai1 – ENGINE OIL FILL2 – ENGINE COOLANT RECOVERY CONTAINER

Fig. 16 Coolant Level1 – COOLANT RECOVERY CONTAINER

17). Use only 50/50 concentration of ethylene glycoltype antifreeze and water

COOLANT LEVEL—SERVICING

NOTE: The cooling system is closed and designedto maintain coolant level to the top of the radiator.

When servicing requires a coolant level check inthe radiator, the engine must be off and not underpressure. Drain several ounces of coolant from theradiator drain cock while observing the CoolantRecovery Container. Coolant level in the containershould drop slightly. Then remove the radiator cap,(Fig. 17). The radiator should be full to the top. Ifnot, and the coolant level in the recovery container isat the ADD mark there is a air leak in the recoverysystem. Check hose or hose connections to the recov-ery container, radiator filler neck or the pressure capseal to the radiator filler neck for leaks.

and Pressure Cap Locations3 – ENGINE OIL DIPSTICK4 – COOLING SYSTEM PRESSURE CAP

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SERVICE PROCEDURES (Continued)

OOLING SYSTEM—DRAINING

OTE: Drain, flush, and fill the cooling system athe mileage or time intervals specified in Group 0,ubrication and Maintenance. If the solution is dirty,usty, or contains a considerable amount of sedi-ent; clean and flush with a reliable cooling system

leaner. Care should be taken in disposing of thesed engine coolant from your vehicle. Check gov-rnmental regulations for disposal of used engineoolant.

Without removing radiator pressure cap andith system not under pressure:(1) Shut engine off and turn draincock counter-

lockwise to open (Fig. 18).(2) The coolant reserve tank should empty first,

hen remove the pressure cap. (if not, Refer to Test-ng Cooling System for leaks).

OOLING SYSTEM—REFILLINGFirst clean system to remove old glycol, see Cooling

ystem Cleaning.Fill system with 50/50 glycol/water mix. Use anti-

reeze described in Coolant section.Continue filling system until full, this provides bet-

er heater performance. Be careful not to spilloolant on drive belts or the generator.Fill coolant reserve/recovery system to at least the

ULL HOT mark with 50/50 solution. It may be nec-ssary to add coolant to the reserve/recovery con-ainer after three or four warm-up/cool down cycleso maintain coolant level between the FULL HOTnd ADD marks; if any trapped air was removedrom the system.

Fig. 18 Cooling System Drain Cock Location1 – DRAIN COCK

REMOVAL AND INSTALLATION

WATER PUMP

REMOVAL(1) Raise vehicle on a hoist. Remove right inner

splash shield.(2) Remove accessory drive belts. Refer to proce-

dure in this section.(3) Drain cooling system. Refer to Cooling System

Draining in this section.(4) Remove power steering pump attaching bolts

and set pump and assembly aside. Power steeringlines do not need to be disconnected.

(5) Remove upper and lower torque isolator struts.(6) Support engine from the bottom and remove

right engine mount attaching bolt.(7) Remove right engine mount bracket.(8) Remove timing belt and timing belt tensioner.

Refer to Group 9, Engine for procedures.(9) Remove camshaft sprocket and rear timing belt

cover. Refer to Group 9, Engine for procedures.(10) Remove water pump attaching screws to

engine and remove pump (Fig. 19).

INSTALLATION(1) Apply Mopart Dielectric Grease to O-ring

before installation.(2) Install new O-ring gasket in water pump body

O-ring groove (Fig. 20).

CAUTION: Make sure O-ring gasket is properlyseated in water pump groove before tighteningscrews. An improperly located O-ring may causedamage to the O-ring, resulting in a coolant leak.

(3) Assemble pump body to block and tightenscrews to 12 N·m (105 in. lbs.). Pressurize coolingsystem to 15 psi with pressure tester and checkwater pump shaft seal and O-ring for leaks.

Fig. 19 Water Pump1 – CYLINDER BLOCK2 – PUMP BODY

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REMOVAL AND INSTALLATION (Continued)

(4) Rotate pump by hand to check for freedom ofovement.(5) Install rear timing belt cover and camshaft

procket.(6) Install timing belt tensioner and timing belt.efer to Group 9, Engine for procedure.(7) Install right engine mount bracket. Refer toroup 9, Engine for procedure.(8) Install upper and lower torque isolator struts.efer to Group 9, Engine for procedure.(9) Fill cooling system. Refer to procedures in this

ection.(10) Install accessory drive belts. Refer to proce-

ure in this section.(11) Perform camshaft and crankshaft timing

elearn procedure as follows:• Connect the DRB scan tool to the data link

diagnostic) connector. This connector is located inhe passenger compartment; at the lower edge ofnstrument panel; near the steering column.

• Turn the ignition switch on and access the “mis-ellaneous” screen.• Select “re-learn cam/crank” option and follow

irections on DRB screen.

ATER PUMP INLET TUBEThe inlet tube connects the water pump to the

adiator and heater core. This tube is sealed by an-ring and held in place by fasteners to the block.

EMOVAL

AUTION: Do not use any sharp tools to removeoses from inlet tube. This may cause the tube to

eak.

(1) Drain cooling system. Refer to procedure inhis section.

(2) Remove upper radiator hose to access the hoseonnections at the inlet tube.

Fig. 20 Water Pump Body1 – IMPELLER2 – PUMP BODY3 – O-RING

(3) Remove intake manifold. Refer to Group 9,Engine for procedure.

(4) Remove lower radiator hose and heater hosefrom the inlet tube.

(5) Remove lower intake manifold support bracket.(6) Remove the inlet tube to the block fasteners.(7) Rotate tube while removing the tube from the

engine block (Fig. 21).

INSTALLATION(1) Inspect the O-ring for damage before installing

the tube into the cylinder block (Fig. 21). ReplaceO-ring as necessary.

(2) Lubricate O-ring with Mopart DielectricGrease and install inlet tube into the cylinder blockopening.

(3) Install inlet tube fasteners and tighten fasten-ers to 12 N·m (105 in. lbs.).

(4) Install intake manifold lower support bracketfasteners and tighten to 12 N·m (105 in. lbs.).

(5) Connect lower radiator hose and heater hose toinlet tube.

(6) Install intake manifold. Refer to Group 9,Engine for procedure.

(7) Install upper radiator hose.(8) Fill cooling system. Refer to procedure in this

section.(9) Pressure system to 104 kPa (15 psi) to check

for leaks.

ENGINE THERMOSTAT

REMOVAL(1) Drain cooling system to the thermostat level or

below.(2) Remove coolant recovery/reserve system hose

and upper radiator hose.

Fig. 21 Water Pump Inlet Tube1 – O-RING2 – WATER PUMP INLET TUBE

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(3) Remove thermostat/engine outlet connectorolts (Fig. 22).(4) Remove thermostat and O-ring assembly.

NSTALLATION(1) Clean all sealing surfaces.(2) Place the new thermostat assembly into the

hermostat housing/outlet connector. Align vent withotch in cylinder head.(3) Install thermostat housing/outlet connector

nto cylinder head and tighten bolts to 12.5 N·m (110n. lbs.).

(4) Install upper radiator hose.(5) Connect the coolant recovery/reserve system

ose.(6) Refill cooling system. Refer to procedure in this

ection.

ADIATOR

EMOVAL

ARNING: DO NOT REMOVE THE CYLINDERLOCK PLUG OR THE RADIATOR DRAINCOCKITH THE SYSTEM HOT AND UNDER PRESSUREECAUSE SERIOUS BURNS FROM COOLANT CANCCUR.

(1) Disconnect negative cable from battery.(2) Drain cooling system. Refer to procedure in

his section.(3) Remove upper radiator hose from the radiator.(4) Disconnect and cap automatic transmission

oses, if equipped.

Fig. 22 Thermostat/Engine Outlet Connector1 – PRESSURE CAP2 – THERMOSTAT HOUSING/ENGINE OUTLET CONNECTOR3 – THERMOSTAT4 – O-RING5 – VENT FACING UP

(5) Disconnect cooling fan motor electrical connec-tor.

(6) Remove cooling fan module retaining screws,located on the top of the shroud (Fig. 23). Lift shroudup and out of bottom shroud attachment clips sepa-rating shroud from radiator.

(7) Remove the lower radiator hose.(8) Remove upper radiator isolator bracket mount-

ing screws (Fig. 24). Disconnect the engine blockheater wire, if equipped.

(9) Remove the air conditioning condenser attach-ing screws located at the front of the radiator, ifequipped (Fig. 25), then lean condenser forward.

NOTE: It is not necessary to discharge the air con-ditioning system to remove the radiator.

Fig. 23 Fan Module Mounting1 – SCREWS2 – LOWER MOUNTS3 – FAN MOTOR ELECTRICAL CONNECTOR

Fig. 24 Radiator Mounting1 – UPPER RADIATOR HOSE2 – UPPER RADIATOR MOUNTS

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(10) Radiator can now be lifted free from engineompartment. Care should be taken not to dam-ge radiator cooling fins or water tubes duringemoval.

NSTALLATION(1) Slide radiator down into position behind radia-

or support (yoke).(2) Attach air conditioning condenser to radiator, if

quipped (Fig. 25), with four mounting screws.ighten screws to 5.4 N·m (50 in. lbs.). Then seat theadiator assembly lower rubber isolators into theounting holes provided in the lower crossmember.(3) Install and tighten radiator isolator mounting

racket screws to 10 N·m (90 in. lbs.) (Fig. 24). Theadiator should have clearance to move up, approxi-ately 5–8 mm (0.20–0.31 in.) after assembled.(4) Install lower radiator hose. Align the hose and

osition the clamp so it will not interfere with engineomponents.(5) Connect automatic transmission hoses, if

quipped. Tighten hose clamps to 2 N·m (18 in. lbs.).(6) Slide fan module down into clip(s) on lower

adiator flange (Fig. 23). Install retaining screws andighten to 7.5 N·m (65 in. lbs.).

(7) Connect the cooling fan motor electrical connec-or.

(8) Install upper radiator hose. Align the hose andosition the clamp so they will not interfere with thengine or the hood.(9) Connect negative cable to battery.(10) Fill cooling system with coolant. Refer to pro-

edure in this section.(11) Operate engine until it reaches normal operat-

ng temperature. Check cooling system and auto-atic transmission for correct fluid levels.

ig. 25 A/C Condenser to Radiator Mounting Screws1 – AIR CONDITIONING CONDENSER TO RADIATOR

MOUNTING SCREWS2 – LOWER ISOLATOR MOUNTS

RADIATOR DRAINCOCK

REMOVAL(1) Turn the drain cock stem counterclockwise to

unscrew the stem. When the stem is unscrewed tothe end of the threads, pull the stem (Fig. 26) fromthe radiator tank.

INSTALLATION(1) Push the draincock assembly body into the

tank opening.(2) Tighten the draincock stem by turning clock-

wise to 2.0-2.7 N·m (18-25 in. lbs.).

COOLING FAN MODULEAll models use a single speed electric motor driven

cooling system fan. The fan module includes a motor,fan blade, and support shroud. The module is fas-tened to the radiator by screws.

REMOVAL

WARNING: DO NOT REMOVE THE CYLINDERBLOCK PLUG OR THE RADIATOR DRAINCOCKWITH THE SYSTEM HOT AND UNDER PRESSUREBECAUSE SERIOUS BURNS FROM COOLANT CANOCCUR.

(1) Disconnect negative cable from battery.(2) Drain cooling system below upper radiator hose

level. Refer to procedure in this section.(3) Remove upper radiator hose from radiator (Fig.

27).(4) Disconnect fan module electrical connector.(5) Remove fan module screws from radiator (Fig.

28).(6) Lift fan shroud up and out of lower shroud

attachment clips.(7) Refer to Disassembly and Assembly in this sec-

tion for fan module sub-component service proce-dures.

Fig. 26 Draincock1 – DRAIN COCK BODY2 – DRAIN COCK HOUSING

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NSTALLATION(1) Install the fan module into the clips on the

ower radiator tank.(2) Install the fan module retaining screws and

ighten to 7.5 N·m (65 in. lbs.).(3) Connect fan module electrical connector. Foriring diagrams of fan motor systems, refer toroup 8W, Wiring Diagrams.(4) Install the upper radiator hose to radiator (Fig.

7). Align hose and position clamp so it will notnterfere with the engine or the hood.

(5) Connect negative cable to battery.(6) Fill cooling system. Refer to procedure in this

ection.

Fig. 27 Upper Radiator Hose1 – UPPER RADIATOR HOSE2 – UPPER RADIATOR MOUNTS

Fig. 28 Fan Module—Removal/Installation1 – SCREWS2 – LOWER MOUNTS3 – FAN MOTOR ELECTRICAL CONNECTOR

COOLANT RECOVERY CONTAINER

REMOVAL(1) Disconnect recovery hose from water outlet

connector/thermostat housing (Fig. 29).(2) Remove container attaching fasteners (Fig. 30).(3) Remove coolant recovery container.

INSTALLATION(1) Install coolant recovery container and tighten

fasteners to 4 N·m (35 in. lbs.) (Fig. 30).

Fig. 29 Recovery Container Hose1 – RECOVERY HOSE2 – ENGINE COOLANT RECOVERY CONTAINER3 – PRESSURE CAP

Fig. 30 Coolant Recovery Container1 – COOLANT RECOVERY CONTAINER2 – SCREW3 – NUT

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(2) Connect recovery hose to water outlet connec-or/thermostat housing (Fig. 29).

(3) Fill container to proper level. Refer to Coolingystem Refilling in this section.

NGINE BLOCK HEATER

EMOVAL(1) Drain coolant from radiator and cylinder block.efer to Cooling System Draining in this section forrocedure.(2) Detach power cord plug from heater (Fig. 31).(3) Loosen screw in center of heater. Remove

eater assembly (Fig. 31).

NSTALLATION(1) Thoroughly clean core hole and heater seat.(2) Insert heater assembly with element loop posi-

ioned upward (Fig. 31).(3) With heater seated, tighten center screw

ecurely to assure a positive seal.(4) Connect power cord to block heater (Fig. 31).(5) Fill cooling system with coolant to the proper

evel, vent air, and inspect for leaks.


ACCESSORY DRIVE BELTS

POWER STEERING PUMP AND AIR CONDITIONINGCOMPRESSOR BELT

REMOVAL(1) Using a 17 mm wrench, rotate belt tensioner

clockwise (Fig. 33) until belt can be removed frompower steering pump pulley. Gently, release springtension on tensioner.

(2) Remove belt (Fig. 34).

INSTALLATION(1) Install belt (Fig. 34) over all pulleys except for

the power steering pump pulley.(2) Using a 17 mm wrench, rotate belt tensioner

clockwise (Fig. 33) until belt can be installed ontopower steering pulley. Release spring tension ontobelt.

NOTE: When installing drive belt onto pulleys,make sure that belt is properly routed and allV-grooves make proper contact with pulley grooves.

(3) After belt is installed, inspect belt length indi-cator marks (Fig. 35). The indicator mark should bewithin the minimum belt length and maximum beltlength marks. On a new belt, the indicator markshould align approximately with the nominal beltlength mark.

Fig. 32 Accessory Drive Belts1 – GENERATOR BELT2 – AUTOMATIC BELT TENSIONER3 – POWER STEERING PUMP/A/C COMPRESSOR BELT



GENERATOR BELT

REMOVAL(1) Remove power steering pump/air conditioning

compressor drive belt.(2) Loosen pivot bolt, then locking nut and adjust-

ing bolt (Fig. 36).(3) Remove generator belt.

NOTE: When installing drive belt onto pulleys,make sure that belt is properly routed and allV-grooves make proper contact with pulley grooves.

INSTALLATION(1) Install belt and/or adjust belt tension by tight-

ening adjusting bolt. Adjust belt to specificationshown in Belt Tension Chart.

NOTE: Due to space limitations, the use of a belttension gauge is limited. Therefore, measure thebelt deflection at the center span of the generatorbelt. Refer to Belt Tension Chart for specifications.

(2) Tighten pivot bolt to 54 N·m (40 ft. lbs.) andlocking nut to 54 N·m (40 ft. lbs.) (Fig. 36).

Conditioning Belt6 – P/S PULLEY7 – TENSIONER PULLEY8 – A/C PULLEY9 – CRANKSHAFT PULLEY

Fig. 33 Accessory Belt—Removing1 – 17mm WRENCH

Fig. 34 Power Steering/Air1 – BELT2 – P/S PULLEY3 – TENSIONER PULLEY4 – CRANKSHAFT PULLEY5 – BELT

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(3) Install power steering pump and A/C compres-or drive belt.

UTOMATIC BELT TENSIONER & PULLEYThe automatic belt tensioner (Fig. 37) maintains

roper tension on the power steering and air condi-ioning belt. The tensioner is serviced with thengine mount bracket assembly. The tensioner pulleyan be serviced.

OTE: Slight axial movement of the tensioner arms normal. Tensioner arm should move freely and

aintain 50–70 lb. tension on belt.

Fig. 35 Belt Length Indicator Marks1 – AUTOMATIC BELT TENSIONER2 – BELT LENGTH INDICATOR3 – MAXIMUM BELT LENGTH4 – NOMINAL BELT LENGTH5 – MINIMUM BELT LENGTH
REMOVAL
(1) Remove engine mount bracket assembly. Referto Group 9, Engine for procedure.

(2) Remove tensioner pulley mounting bolt.(3) Remove pulley.

INSTALLATION(1) Install tensioner pulley and bolt. Tighten bolt

to 27 N·m (20 ft. lbs.).(2) Install engine mount bracket assembly. Refer

to Group 9, Engine for procedure.

DISASSEMBLY AND ASSEMBLY

COOLING FAN MODULEThe cooling fan module consist of the following

three components: fan, fan motor, and shroud.

Fig. 36 Generator Belt Adjustment1 – ADJUSTING BOLT2 – LOCKING NUT3 – PIVOT BOLT

BELT TENSION CHART

AccessoryDrive Belt

Belt Tension Belt Deflectionat Center Span*

Power SteeringPump and A/C

CompressorDynamic Tensioner

GeneratorNew 135 lb. 4.5 mm (0.18 in.)

Used 100 lb. 5.5 mm (0.22 in.)

* Belt deflection is measured at the center of the beltspan with 4.5 kg (10 lb.) force.

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DISASSEMBLY AND ASSEMBLY (Continued)

ANThere are no repairs to be made to the fan. If the

an is warped, cracked, or otherwise damaged, itust be replace with only the recommended part for

dequate strength, performance and safety.

EMOVAL(1) Remove cooling fan module. Refer to procedure

n this section.(2) Remove fan hub retaining nut (Fig. 38).(3) Remove fan from motor shaft.

NSTALLATION(1) Install fan on motor shaft.(2) Install fan retaining nut and tighten to 3.8·m (34 in. lbs.) (Fig. 38).(3) Install cooling fan module. Refer to procedure

n this section.

AN MOTOR


n this section.(2) Remove fan from motor shaft.(3) Remove screw attaching the in-rush current

uppressor (Fig. 39).(4) Remove screws attaching motor to shroud (Fig.

9).(5) Remove fan motor.

Fig. 37 Automatic Belt Tensioner1 – GENERATOR BELT2 – AUTOMATIC BELT TENSIONER3 – POWER STEERING PUMP/A/C COMPRESSOR BELT

INSTALLATION(1) Install fan motor on shroud and tighten screws

to 3.8 N·m (34 in. lbs.) (Fig. 39).(2) Install screw attaching the in-rush current sup-

pressor and tighten to 2.6 N·m (23 in. lbs.) (Fig. 39).(3) Install fan on motor shaft.(4) Install cooling fan module. Refer to procedure

in this section.

Fig. 38 Fan—Removal and Installation1 – FAN2 – NUT3 – SHROUD ASSEMBLY

Fig. 39 Fan Motor—Removal and Installation1 – FAN MOTOR SCREWS2 – IN RUSH CURRENT SUPPRESSOR SCREW

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DISASSEMBLY AND ASSEMBLY (Continued)

HROUD


n this section.(2) Remove fan and fan motor as previously

escribed.

NSTALLATION(1) Install fan motor and fan as previously

escribed.(2) Install cooling fan module. Refer to procedure

n this section.

LEANING AND INSPECTION

ATER PUMPReplace water pump body assembly if it has any of

hese defects:(1) Cracks or damage on the body.(2) Coolant leaks from the shaft seal, evident by

oolant traces on the pump body.(3) Loose or rough turning bearing.(4) Impeller rubs either the pump body or the

ngine block.(5) Impeller loose or damaged.(6) Sprocket or sprocket flange loose or damaged.

CCESSORY DRIVE BELT INSPECTIONBelt replacement under any or all of the following

onditions is required, excessive wear, frayed cords orevere glazing.Poly-V Belt system may develop minor cracks

cross the ribbed side. These minor cracks are con-idered normal and acceptable. Cracks parallel areot (Fig. 40).

OTE: Do not use any type of belt dressing orestorer on Poly-V Belts.

OOLING SYSTEM CAPHold the cap in your hand, right side up (Fig. 41).

he vent valve at the bottom of the cap should openith a slight pull. If the rubber gasket has swollen,reventing the valve from opening, replace the cap.If any light can be seen between vent valve and

he rubber gasket, replace the cap. Use only aeplacement cap that has a spring to hold theent shut.A replacement cap must be of the type designed for

oolant reserve systems. This design ensures systemressurization.

COOLING SYSTEM CLEANING(1) Drain cooling system. Refer to Cooling System

Draining in this section for procedure.(2) Refill with clean water. Refer to Cooling Sys-

tem Refilling in this section for procedure.(3) Run engine with radiator cap installed until

upper radiator hose is hot.(4) Stop engine and drain water from system. If

water is dirty, fill, run and drain the system againuntil water runs clear.

RADIATOR FLUSHING(1) Drain cooling system. Refer to Cooling System

Draining in this section for procedure.(2) Remove radiator hoses from engine.(3) Install suitable flushing gun in radiator lower

hose.(4) Fill radiator with clean water and turn on air

in short blasts.

CAUTION: Internal radiator pressure must notexceed 138 kPa (20 psi) as damage to radiator mayresult. Continue this procedure until water runsclear.

ENGINE FLUSHING(1) Drain radiator. Refer to Cooling System Drain-

ing in this section for procedure.(2) Remove hoses from radiator.

Fig. 40 Drive Belt Wear Pattern1 – NORMAL CRACKS BELT OK2 – NOT NORMAL CRACKS REPLACE BELT

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CLEANING AND INSPECTION (Continued)

(3) Remove engine thermostat and reinstall ther-

Fig. 41 Cooling System Pressure Cap1 – PRESSURE RATING2 – FILLER NECK SEAL3 – PRESSURE VALVE4 – VACUUM VENT VALVE (SHOWN IN SEALING POSITION)

ostat housing. A gasket may be needed to seal the

housing to cylinder head because the seal is part ofthermostat.

(4) Install suitable flushing gun to thermostathousing hose. Turn on water, and when engine isfilled, turn on air, but no higher than 138 kPa (20psi) in short blasts. Allow engine to fill betweenblasts of air. Continue this procedure until waterruns clean.

(5) Install thermostat and fill cooling system.Refer to Cooling System Refilling in this section forprocedure.

REVERSE FLUSHINGReverse flushing of the cooling system is the forc-

ing of water through the cooling system, using airpressure in a direction opposite to that of the normalflow of water. This is only necessary with dirty sys-tems and evidence of partial plugging.

CHEMICAL CLEANINGOne type of corrosion encountered with aluminum

cylinder heads is aluminum hydroxide deposits. Cor-rosion products are carried to the radiator and depos-ited when cooled off. They appear as dark grey whenwet and white when dry. This corrosion can beremoved with a two part cleaner (oxalic acid andneutralizer) available in auto parts outlets. Followmanufacturers directions for use.

ADJUSTMENTS

BELT TENSIONFor belt tension adjustment procedure, refer to

Accessory Drive Belt Removal and Installation proce-dure.

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PECIFICATIONS

OOLING SYSTEM CAPACITY

ORQUE SPECIFICATIONS

6.2 Liters (6.5 qts.)

CAPACITY, Includes Heater and Coolant ReserveSystem

DESCRIPTION N·m Ft.Lbs.

In.Lbs.

A/C Condenser to Radiator—Screws

5.4 — 50

Automatic Belt TensionerPulley—Bolt

27 20 —

Coolant Recovery Container—Nut/Screw

4 — 35

Fan Module to Radiator—Screws

7.2 — 65

Fan Motor to Shroud—Screws 3.8 — 34

Fan Blade to Motor Shaft—Nut

3.8 — 34

In Rush Current Supressor—Screw

2.6 — 23

Generator Mounting—PivotBolt

54 40 —

Generator Mounting—LockingNut

54 40 —

Radiator (Cooling Module) toBody—Screws

10 — 90

Thermostat Housing/WaterOutlet Connector—Screws

12 — 105

Transmission Hose—Clamps 2 — 18

Water Pump to EngineBlock—Bolts

12 — 105

Water Pump Inlet Tube toEngine Block—Bolts

12 — 105

PECIAL TOOLS

OOLING

Hose Clamp Pliers 6094

Coolant Refractometer 8286

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